Roof structure adjustable support frame system

ABSTRACT

A roof structure adjustable support frame system comprising a plurality of joist rails configured to adjust longitudinally; a plurality of side rails configured to adjust longitudinally between the plurality of joist rails; a plurality of corner rail connectors configured to couple a side rail to a joist rail; and a plurality of adjustable joist rail connectors. The plurality of adjustable joist rail connectors comprise a joist rail attachment configured to removably attach to an end of the joist rail, an extension support member extending longitudinally from a first end of the joist rail attachment, a hook assembly configured to move longitudinally along the extension support member and engage a roof joist to couple the joist rail to the joist; and a movable stop configured to secure the hook assembly against the roof joist.

BACKGROUND OF THE INVENTION

The present invention relates to the field of roof support frames. In particular, the present invention relates a roof structure adjustable support frame system with an adjustable joist rail connector.

Buildings, especially commercial buildings, are often required to have roof access holes to allow various objects and structures, such as heating, air conditioning, and ventilation ducts, electrical cables, pipes, skylights, and smoke stacks, to pass through their roofs. However, once a hole is cut into a roof, it is necessary to provide additional structural support around the hole.

If no additional support is provided, the roof may be damaged or weakened when a load is applied to the roof.

Roof support frames have been developed to provide additional support to roofs with access holes. In general, support frames surround an access hole and transmit loads to adjacent trusses and joists. However, support frames have been relatively expensive to manufacture and install. The requirements of each building and the dimensions of each access hole are different. Consequently, support frames have been custom designed and manufactured for each site. What has long been needed is a means by which one roof support may be adapted to be used in different situations and to fit access holes of many different sizes.

The design of most prior art roof support frames also requires the frames to be assembled in an off-site manufacturing facility. Many support frames are welded together then shipped to building sites and installed. However, the assembled frames are bulky, requiring a great deal of space, which significantly increases the shipping and handling costs. What is needed is a support frame that may be shipped unassembled and then easily assembled at a building site. This would reduce shipping and handling costs by allowing a greater number of frames to be shipped in the same space.

Any discussion of prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.

BRIEF SUMMARY OF THE INVENTION

The problems discussed above are overcome by the present invention which provides a roof structure adjustable support frame system for attaching a roof support frame to existing roof joists. The roof structure adjustable support frame system comprises an adjustable joist rail connector comprises an joist rail attachment with a substantially T-shaped cross-section or, alternatively, an L-shaped cross-section with horizontal and vertical members. The horizontal and vertical members abut the upper and side surfaces of the joist rails, respectively. The vertical member may comprise a fastener hole or slot for attaching the adjustable joist rail connector to a joist rail of the roof support frame.

An extension support member preferably extends longitudinally from the joist rail attachment. A movable stop is threadably attached onto the extension support member. In between the joist rail attachment and the retaining nut, a hook assembly configured to move longitudinally along the extension support member and engage the joist on which the roof support frame is mounted. The hook assembly comprises a hook coupled to a ring.

The adjustable joist rail connector is a part of a roof structure adjustable support frame system. The roof structure adjustable support frame system comprises a plurality of joist rails, a plurality of side rails, a plurality of corner rail connectors, and a plurality of adjustable joist rail connectors. The joist rails and the side rails are preferably adjustable longitudinally. The joist rails preferably connect to the existing roof structure joists with the adjustable joist rail connectors. The side rails preferably connect the joist rails together using the plurality of corner rail connectors.

These adjustable joist rail connectors facilitate adjustment and assembly since the hooks are adjustable to support the joist rails at any desired length after the fasteners are tightened. Alternately, the adjustable joist rail connectors may be replaced by joist rail bridge members to interconnect the adjustable roof support frame to another roof support frame on an opposite side of one of the joists. That is, a joist rail bridge member can be substituted for the adjustable joist rail connector, span a joist, and support a first joist rail of a first roof support frame and a first joist rail of a second roof support frame on a joist that runs between the two frames.

Other deficiencies of the past are also overcome as can be appreciated by a review of the descriptions and drawings set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 shows a top perspective view of a roof with a structure protruding through an access hole;

FIG. 2 shows a top perspective cutaway view of a roof with the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

FIG. 3 shows a perspective view of an adjustable joist rail connector of the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

FIG. 4 shows a perspective view of an adjustable joist rail connector of the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

FIGS. 5A and 5B shows a perspective view of an alternate embodiment of an adjustable joist rail connector of the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

FIG. 6 shows an exploded perspective view of the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

FIG. 7 shows a partially exploded perspective view of an adjustable joist rail connector on the end of a joist rail of the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

FIG. 8 shows a partially exploded perspective view of a corner rail connector attaching a joist rail to a side rail of the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

FIGS. 9A and 9B shows a side and end view of the joist rails and side rails of the Adjustable Joist Rail Connector for a Roof Support Frame according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following description of the invention taken in conjunction with the accompanying drawings.

Referring now to the figures, FIG. 1 shows a standard roof 10 having trusses or joists 20 and a structure 30 projecting out of an access hole 40. The structure 30 may be any of a large number of objects or devices that are used on rooftops, such as a heating, air conditioning, or ventilation duct, a smokestack, electrical cables and wires, pipes, or a skylight. The roof 10 may be constructed using various materials well known in the art.

As shown in FIG. 2, the roof structure adjustable support frame system 100 is attached to existing joists or trusses 20 underneath the existing roof 10. The roof structure adjustable support frame system 100 is configured to span the space between the existing joists or trusses 20 to provide structural support to the roof 10 across the entire space between the existing joists or trusses 20. The roof support frame system 100 is preferably manufactured from heavy gauge steel, however, other materials such as aluminum or iron may be used.

As further shown in FIG. 2 a roof structure adjustable support frame system 100 comprising a plurality of joist rails 110, a plurality of side rails 120, a plurality of corner rail connectors 130 configured to couple a side rail to a joist rail, and a plurality of adjustable joist rail connectors 140. The plurality of joist rails 110 are configured to adjust longitudinally between the existing roof joists 20, and the plurality of side rails 120 are configured to adjust longitudinally between the plurality of joist rails 110.

As further shown in FIG. 2, the plurality of joist rails 110 preferably couple the roof structure adjustable support frame 100 to the existing roof joists 20 using the plurality of adjustable joist rail connectors 140. The joist rail connectors 140 are attached to the ends of the joist rails 110 and extend over the existing roof joist rail 20 to couple or hook the roof structure adjustable support frame system 100 to the existing roof joist 20.

As shown in FIG. 3-4, the adjustable joist rail 140 connector comprises a joist rail attachment 150, an extension support member 160 extending longitudinally away from an end 152 of the joist rail attachment 150, a hook assembly 170, and a movable stop 180. The joist rail attachment 150 is configured to couple the adjustable joist rail connector 140 to an end portion 195 of the joist rail 110.

As further shown in FIGS. 3-4, the hook assembly 170 is comprised of a ring 172 and a hook 174 attached to an outside surface 176 of the ring. The ring 172 is configured to slide along the threaded rod 160 such that the hook 174 engages the existing roof joist on an edge opposite the joist rail. The movable stop 180 is configured to thread onto the threaded rod 160 and secure the hook assembly 170 against the existing roof joist, thus securing the roof support frame system to the roof.

As further shown in FIG. 3-4, the extension support member 160 is attached to an end of the joist rail attachment 150 such that it extends away from the joist rail attachment 150 and over the existing roof joist the adjustable roof support frame system is being attached to. The extension support member 160 is preferably welded to the joist rail attachment 150. However, other methods of coupling the extension support member 160 to the joist rail attachment 150 should be considered. Additionally, the extension support member 160 preferably comprises at least a portion that is threaded.

As further shown in FIG. 3, the joist rail attachment 150 is configured in an “L” shape comprising a horizontal section 156 and a vertical section 154 extending downward from at least one side of the horizontal section 156. Preferably, the vertical section 154 comprises a plurality of openings 158 configured to match with openings on a joist rail 110 such that a fastener will couple the joist rail attachment 150 of the adjustable joist rail connector 140 to the end of the joist rail 110.

On an alternate embodiment shown in FIG. 4, the joist rail attachment 150 is preferably “T” shaped comprising a horizontal section 156 and a vertical section 154 extending downward from the about a middle portion of the horizontal section 156. Preferably, the vertical section 154 comprises a plurality of openings configured 158 to match with openings on a joist rail such that a fastener will couple the joist rail attachment 150 of the adjustable joist rail connector 140 to the end of the joist rail 110.

The plurality of openings 158 on the vertical section 154 of the joist rail attachment 150 are preferably square shaped and configured to accept a square necked fastener, such as a carriage bolt.

As further shown in FIGS. 3-4, the adjustable joist rail connector 140 further comprises a movable stop 180. The movable stop 180 is preferably a lock nut sized to thread onto the extension support member 160 on the end opposite the joist rail attachment 150. The movable stop 180 is threaded onto the threaded portion and butted against the hook assembly 170 to secure the hook assembly against the roof joist.

An alternate embodiment of the adjustable joist rail connector 140 is shown in FIGS. 5A and 5B, the alternate embodiment of the adjustable joist rail connector 140 comprises a joist rail attachment 150 and a roof truss coupler 200. The joist rail attachment 150 is comprised of a horizontal plate 156 and a vertical plate 154 configured to removably attach the adjustable joist rail connector 140 to an end of a joist rail 110. The joist rail attachment 150 comprises a first end and a second end 152, where the second end 152 comprises a cut-out portion 206 near a top section of the second end 152.

As further shown in FIGS. 5A and 5B, a roof truss coupler 200 is on the first end of the joist rail attachment 150 under the cut-out portion 158. The roof truss coupler 200 comprises a horizontal plate 202 and two set screws 204 configured to engage a roof truss of an existing roof, such as a C-channel or angle iron. The two set screws 204 are located on either side of the joist rail attachment vertical plate 154. The roof truss coupler 200 comprises a female threaded portion 208 as part of the horizontal plate 202. The female threaded portion 208 may be a nut sized to accept the set screw 204, or a female threaded hole in the horizontal plate 202 where the female threaded hole is sized to accept the set screw 204.

As further shown in FIGS. 5A and 5B, the joist rail attachment 150 is configured in an “L” shape comprising a horizontal section 156 and a vertical section 154 extending downward from at least one side of the horizontal section 156. Preferably, the vertical section 154 comprises a plurality of openings 158 configured to match with openings on a joist rail 110 such that a fastener will couple the joist rail attachment 150 of the adjustable joist rail connector 140 to the end of the joist rail 110.

In an alternate embodiment, the joist rail attachment 150 is preferably “T” shaped comprising a horizontal section 156 and a vertical section 154 extending downward from the about a middle portion of the horizontal section 156. Preferably, the vertical section 154 comprises a plurality of openings configured 158 to match with openings on a joist rail such that a fastener will couple the joist rail attachment 150 of the adjustable joist rail connector 140 to the end of the joist rail 110.

As shown in FIGS. 6 and 7, the roof structure adjustable support frame system 100 comprises a first and second joist rail 110, each configured to adjust in length. The first and second joist rails 110 are configured to fit between existing roof joists of a roof and attach to the existing roof joists by using the plurality of adjustable joist rail connectors 140.

As further shown in FIGS. 6 and 7, the plurality of joist rails 110 are preferably configured to be adjustable longitudinally. Each joist rail comprises an inner joist rail 112 and an outer joist rail 114 configured to slidably receive the inner joist rail 112. The outer joist rail 114 is preferably a “C” shaped channel such that the inner joist rail 112 fits within the open portion of the “C” channel. However, the outer joist rail 114 could be an L-shaped, such as angle iron.

As further shown in FIGS. 6 and 7, the outer joist rail 114 and the inner joist rail 112 preferably further comprise at least one fastener slot 116 and at least one fastener hole 118. The at least one fastener slot may be on the outer joist rail 114 or on the inner joist rail 112. Additionally, the at least one fastener hole 118 will be on the opposite joist rail that the at least one fastener slot 116 is on such that when the inner joist rail 112 is slidably adjusted along the outer joist rail 114, the at least one fastener hole 118 will line up with the at least one fastener slot 116 such that when the desired length of the joist rail 110 is reached, the fastener is put through the at least one fastener hole 118 and through the at least one fastener slot 116 and tightened to secure the final length of the joist rail 110. Alternately preferably, both the inner and outer joist rails comprise at least one fastener slot 116 configured to line up together when the inner joist rail 112 is slidably fit within the recess of the outer joist rail 114 and the desired longitudinal length between the existing roof joists is achieved.

Similarly, as further shown in FIG. 6, the plurality of side rails 120 comprise an inner side rail 122 and an outer side rail 124 configured to allow the inner side rail 122 to slidably move longitudinally in relation to the outer side rail 124. The outer side rail 124 and the inner side rail 122 preferably further comprise at least one fastener slot 126 and at least one fastener hole 128. The at least one fastener slot may be on the outer side rail 124 or on the inner side rail 122. Additionally, the at least one fastener hole 128 will be on the opposite side rail that the at least one fastener slot 126 is on such that when the inner side rail 122 is slidably adjusted along the outer side rail 124, the at least one fastener hole 128 will line up with the at least one fastener slot 126 such that when the desired length of the side rail 120 is reached, the fastener is put through the at least one fastener hole 128 and through the at least one fastener slot 126 and tightened to secure the final length of the side rail 120 between the plurality of joist rails 110.

As shown in FIGS. 6-8, both the inner and outer side rails 120 each comprise at least one fastener slot 126 configured to line up together when the inner side rail 122 is slidably fit within the recess of the outer side rail 124 and the desired longitudinal length between the joist rails 110 is achieved. The at least one fastener slot 126 is preferably oriented in a horizontal direction along the length of the rails.

As further shown in FIGS. 6 and 8, the roof structure adjustable frame support frame system 100 comprises a plurality of corner rail connectors 130 configured to couple the first or second side rail to the first or second joist rail. The corner rail connectors 130 are preferably an “L” shaped bracket further comprising fastener holes. The corner rail connectors 130 comprise flat surfaces configured to abut the surfaces of the joist rails 110 and side rails 120, thus attaching the side rails 120 to the joist rails 110 at a roughly 90 degree angle using fasteners 190. The joist rails and side rails are coupled together such that the channels of the inner joist rail and the inner side rail face outwards.

Further, as shown in FIGS. 9A and 9B, the inner side rail 122 and outer side rail 124 preferably further comprise at least one fastener slot 126 and at least one fastener hole 128. The at least one fastener slot 126 may be on the inner side rail 122 or on the outer side rail 124. Additionally, the at least one fastener hole 128 will be on the opposite side rail that the at least one fastener slot 126 is on such that when the inner side rail 122 is slidably adjusted along the outer side rail 124, the at least one fastener hole 128 will line up with the at least one fastener slot 126 such that when the desired length of the side rail 120 is reached, the fastener 190 is inserted through the at least one fastener hole 128 and through the at least one fastener slot 126 and tightened to secure the final length of the side rail 120. The distance between the fastener slots 126 and/or the fastener holes 128 may change as necessary.

Further, as shown in FIGS. 9A and 9B, the inner joist rail 112 and outer joist rail 114 preferably further comprise at least one fastener slot 116 and at least one fastener hole 118. The at least one fastener slot 116 may be on the inner joist rail 112 or on the outer joist rail 114. Additionally, the at least one fastener hole 118 will be on the opposite joist rail that the at least one fastener slot 116 is on such that when the inner joist rail 112 is slidably adjusted along the outer joist rail 114, the at least one fastener hole 118 will line up with the at least one fastener slot 116 such that when the desired length of the joist rail 110 is reached, the fastener 190 is inserted through the at least one fastener hole 118 and through the at least one fastener slot 116 and tightened to secure the final length of the joist rail 110.

As further shown in FIGS. 9A and 9B, the fastener hole 118 and 128 is preferably square to accommodate a fastener 190 with a square neck, such as a carriage bolt, to prevent the fastener 190 from spinning. The fasteners 190 used in the adjustable roof support frame are preferably bolts and nuts. However, other types of fasteners can be used that are typical for roof frame construction.

Although the present invention has been described by way of example, it should be appreciated that variations and modifications may be made without departing from the scope of the invention. Furthermore, where known equivalents exist to specific features, such equivalents are incorporated as if specifically referred to in this specification. 

We claim:
 1. An adjustable joist rail connector comprising: a joist rail attachment configured to removably attach the adjustable joist rail connector to an end of a joist rail; an extension support member extending longitudinally from a first end of the attachment portion; a hook assembly configured to move longitudinally along the extension support member and engage a roof joist on which a support frame is mounted, wherein the hook assembly comprises a hook coupled to a ring; and a movable stop at an opposite end of the joist rail attachment, wherein the movable stop is configured to move along the extension support member and engage the hook assembly; wherein, the hook assembly is between the joist rail attachment and the movable stop.
 2. The adjustable joist rail connector of claim 1, wherein the joist rail attachment is “T” shaped comprising a horizontal section and a vertical section extending downward from about a middle of the horizontal section.
 3. The adjustable joist rail connector of claim 1, wherein the joist rail attachment is “L” shaped comprising a horizontal section and a vertical section extending downward from at least one side of the horizontal section.
 4. The adjustable joist rail connector of claim 2, wherein the joist rail attachment comprises a plurality of openings on the vertical section configured to match with openings on a joist rail such that a fastener couples the adjustable joist rail connector to the joist rail.
 5. The adjustable joist rail connector of claim 1, wherein the movable stop is a lock nut sized to threadably move along the extension support member.
 6. The adjustable joist rail connector of claim 3, wherein the joist rail attachment comprises a plurality of openings on the vertical section configured to match with openings on a joist rail such that a fastener couples the adjustable joist rail connector to the joist rail.
 7. The adjustable joist rail connector of claim 6, wherein the plurality of openings are square in shape and configured to accept a square necked fastener.
 8. A roof structure adjustable support frame system comprising: a plurality of joist rails configured to adjust longitudinally between existing roof joists; a plurality of side rails configured to extend longitudinally between the plurality of joist rails; a plurality of corner rail connectors configured to couple a side rail to a joist rail; and a plurality of adjustable joist rail connectors comprising a joist rail attachment configured to removably attach to an end of the joist rail, an extension support member extending longitudinally from a first end of the joist rail attachment, a hook assembly configured to move longitudinally along the extension support member and engage a roof joist to couple the joist rail to the joist; and a movable stop configured to secure the hook assembly against the roof joist; wherein the plurality of joist rails are coupled to the existing roof joists with the plurality of adjustable joist rail connectors; and wherein the plurality of side rails attach to the plurality of joist rails with the plurality of corner rail connectors.
 9. The roof structure adjustable support frame system of claim 8, wherein the plurality of joist rails comprise a respective inner joist rail configured to slide against a corresponding outer joist rail.
 10. The roof structure adjustable support frame system of claim 8, wherein the plurality of side rails comprise a respective inner side rail configured to slide against a corresponding outer side rail.
 11. The roof structure adjustable support frame system of claim 8, wherein the joist rail attachment is “T” shaped comprising a horizontal section and a vertical section extending downward from about a middle of the horizontal section, and wherein the vertical section comprises a plurality of through holes.
 12. The roof structure adjustable support frame system of claim 8, wherein the joist rail attachment is “L” shaped comprising a horizontal section and a vertical section extending downward from at least one side of the horizontal section, and wherein the vertical section comprises a plurality of through holes.
 13. The roof structure adjustable support frame system of claim 9, wherein the inner joist rail comprises a plurality of holes linearly along the about center of a vertical section, and wherein the outer joist rail comprises a plurality of slots linearly along the about center of a vertical section, and wherein the plurality of holes and the plurality of slots are configured to align such that a fastener will tighten the inner joist rail against the outer joist rail.
 14. The roof structure adjustable support frame system of claim 10, wherein the outer side rail comprises a plurality of holes linearly along the about center of a vertical section, and wherein the inner side rail comprises a plurality of slots linearly along the about center of a vertical section, and wherein the plurality of holes and the plurality of slots are configured to align such that a fastener will tighten the inner side rail against the outer side rail.
 15. An adjustable joist rail connector comprising: a joist rail attachment configured to removably attach the adjustable joist rail connector to an end of a joist rail, wherein the joist rail attachment comprises a first end and a second end, and wherein the joist rail second end comprises a cut-out portion near a top section of the second end; a roof truss coupler on a second end of the joist rail attachment under the cut-out portion, the roof truss coupler comprising a horizontal plate and two set screws configured to engage a roof truss of an existing roof.
 16. The adjustable joist rail connector of claim 15, wherein the joist rail attachment is “T” shaped comprising a horizontal section and a vertical section extending downward from about a middle of the horizontal section, and wherein the vertical section comprises a plurality of through holes.
 17. The adjustable joist rail connector of claim 15, wherein the joist rail attachment is “L” shaped comprising a horizontal section and a vertical section extending downward from at least one side of the horizontal section, and wherein the vertical section comprises a plurality of through holes.
 18. The adjustable joist rail connector of claim 16, wherein the plurality of through holes are square shaped and configured to accept a square necked fastener.
 19. The adjustable joist rail connector of claim 17, wherein the plurality of through holes are square shaped and configured to accept a square necked fastener.
 20. The adjustable joist rail connector of claim 15, wherein the cut-out portion and roof truss coupler is configured to accept an edge of a C-channel or angle iron. 